Thermoplastic overmolding

Getelec has taken over KAP Press design and manufacture with an extended development programme
of interest to all in the plastics fabrication sector.

Presses in our current PRECINJECT range are specifically designed for high volume overmolding
and micromolding applications.

Our technical approach to our clients and partners is holistic; our machines, made in the town of
Buc, just outside Paris, France are very often supplied complete with the pre- or mass-production
moulds which we also design.

The Getelec/KAP team is at your disposal for any information you may require about overmolding
and precision micromolding, using our knowledge gained over 20 years’ experience in the field

Why overmolding?

Definition :

Overmolding, also known as insert moulding, is very close to the injection moulding process, since it builds on classic moulding techniques.

This technology is used for both simple and complex parts and it is employed in a great number of industries and areas of application, including automobile, datacomms, electronics, telephony, household goods, aeronautics, cosmetics, designer, and many more.

The basic principle of overmolding is simple. It consists of positioning one part, part A (the insert) in an injection mould and then injecting a substance, material B. It is by filling the mould that the insert is overmolded with material B.

There are various types of insert:

  • metal insert
  • plastics insert
  • composite insert
  • treated and non-treated insert

With this method it is possible to make, in just one process, parts with inserts which, very often, could not be made using traditional methods.
Finally, with overmolding supplementary steps such as assembly or finishing are no longer needed, thus reducing costs.

Why overmolding is so useful

  • Manufacture of sealed parts
    Overmolding guarantees a direct seal, with no need for external gaskets or adhesives, fitting the shape and overmolded material.
  • Complex part fabrication
    In classic technologies such as adding (often by use of force) inserts to moulded parts, problems often crop up such as surface damage or the impossibility of added complex parts or parts with bends.By overmolding directly onto the insert, however, complex parts can be made without having to resort to joining two
    plastic halves or snapping parts together over the insert. This process eliminates problems of supplementary stages (such as supplementary moulded parts, mould design, assembly machines, etc.) and surface issues (such as joint splits).
  • Appearance and design
    With overmolding excellent finishes are possible, using coloured materials and different textures while at the same time dispensing with assembly phases and surface finish problems, without forgetting reproducibility. The product’s functionality can also be guaranteed by the use of overmolding (e.g. curvature radius of a connector, smooth appearance, identification marks, etc.)
  • Manufacture of parts with metal inserts
    Widely used in the datacomms, electronics and automobile sectors, metallic inserts are placed in the mould and are completely embedded in it or emerge from it depending on the required application. They are mostly used for carrying electrical currents (e.g. connectors, sensors, temperature probes, etc.)
  • Elimination of assembly phases
    Assembly is an automatic part of overmolding, and there is no need to design or have a final assembly machine. This cuts down both total fabrication time and costs, while ensuring your product has even better quality.